Splitting Engine Cases Removing Studs

Hey Gang - I've already pulled off the top end of the old 650 motor. Tomorrow morning I am going to be removing the studs and splitting the cases to take to the machine shop for boring to fit the 750 jugs for my 810 kit.

Any quick tips or tricks on simplifying the job? I would prefer if I could leave the bottom half of the case and its innards in the frame if possible. There seems to be enough room to lift the top half of the cases up through the frame once the studs are all removed.

Cheers-Colin Firth-Ontario Canada

'77 Kz 650 Custom - (Miss July on 2006 Kzr Calendar,) Wiseco 810 kit, Kz750 cams, Kz750 intake valves, 750 GPz springs, Ported head, WG Mikuni 28's, Filters, Dyna Ignition and coils, MAC pipe, 13 tooth sprocket, going back to original '77 Moon Dust Silver. Goal is to have a stock-looking bike that will tighten up any loose dental fillings off the light.

ive never seen it done,but i guess stranger things have happened.goodluck;)

Just remember to take off the oil pan and get the "hidden" bolts that hold on the top case, I think theres 6 big ones in there if I remember right.
I didnt remove the cylinder studs tho, they didnt want to budge, and I didnt want to risk stripping the threads.
Scott

Post edited by: 77KZ650, at: 2006/04/08 23:59

you can leave the engine in the frame,
split the cases, but you gotta turn the bike upside down. Its a kaw thingy

:whistle: :woohoo: that was my thought,but was afraid to say it!goodluck,happy wrenching

Might want to take it out of the frame then, when I split my cases, I took care of the bolts "hidden" in the oil pan, then flipped the motor right side up so all the gears/crank would just stay put. the top case will lift right off, leaving everything in the lower case. very simple, no messing around with the tranny.

Thanks gang....

Well I got out in the garage tonight to work on writing my story for tomorrow's deadline with my newspaper. It's quiet out there. I took a look at my bike....and...I had a mental block. O.K. I didn't want to write. So I put down my pen and started wrenching:)

Within 45 minutes I had the entire motor outta the frame and the stripped down powerplant up on the bench. I decided it was the easiest way to go as I will be able to give everything a good cleaning and the frame's finish a few little touch ups.

The funny thing is while I was wrenching I got in the zone and started thinking about my story (slamming City Hallers for their F-up that's going to cost our local taxpayers an extra $18 million on an infrastructure poject.)

I don't know about anyone else, but working on these beautiful old bikes is therapeutic....Zen and the Art of Motorcycle Maintenance.

I'll split the cases tomorrow as I have a story to write and deadline to reach. Piece of cake:)

Cheers-Colin Firth

'77 Kz 650 Custom - (Miss July on 2006 Kzr Calendar,) Wiseco 810 kit, Kz750 cams, Kz750 intake valves, 750 GPz springs, Ported head, WG Mikuni 28's, Filters, Dyna Ignition and coils, MAC pipe, 13 tooth sprocket, going back to original '77 Moon Dust Silver. Goal is to have a stock-looking bike that will tighten up any loose dental fillings off the light.